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Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From...
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Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Structural Integrity of Metals".

Deadline for manuscript submissions: 10 September 2026 | Viewed by 5109

Special Issue Editors

Prof. Dr. Jin Gan

E-Mail Website
Guest Editor
School of Naval Architecture Ocean and Energy Power Engineering, Wuhan University of Technology, Wuhan, China
Interests: structural integrity; fracture mechanics; fatigue analysis; surface strengthment method; residual stress; multiaxial loading; computational modeling; high-strength steels; lightweight alloys; fatigue strength improvement technology
Dr. Huabing Liu

E-Mail Website
Guest Editor
Green & Smart River-Sea-Going Ship Cruise and Yacht Research Center, Wuhan University of Technology, Wuhan, China
Interests: structural integrity; fatigue analysis; surface strengthment method; residual stress; computational modeling; high-strength steels; lightweight alloys
Dr. Lei Ao

E-Mail Website
Guest Editor
Green & Smart River-Sea-Going Ship, Cruise and Yacht Research Center, Wuhan University of Technology, Wuhan 430063, China
Interests: structural integrity; crack damage; multiphysics environment; corrosion fatigue analysis; initial deformation; residual stress; computational modeling; scaled model test; high-strength steels

Special Issue Information

Dear Colleagues,

The structural integrity of metallic components and systems is a cornerstone of engineering design, ensuring safety, reliability, and longevity across industries ranging from aerospace to civil infrastructure. As demands for lightweight, high-performance materials grow, so does the need for innovative approaches to assess and enhance the resilience of metallic structures under static, cyclic, and multiaxial loading conditions. This Special Issue, under the "Structural Integrity of Metals" section, seeks to bridge cutting-edge research with practical applications, fostering advancements in fracture and fatigue assessment methodologies.

Modern challenges in structural integrity call for a multidisciplinary synthesis of experimental, theoretical, and computational tools. From traditional fatigue life prediction models to data-driven techniques leveraging machine learning and big data analytics, the field is rapidly evolving to address complex geometries, scale effects, notch sensitivities, and multiaxial stress states. Furthermore, the interplay between microstructure, mechanical properties, and environmental factors necessitates a holistic understanding of failure mechanisms to optimize material selection and design.

We particularly encourage submissions that combine theoretical rigor with practical relevance, offering actionable insights for industries reliant on metallic structures. Studies addressing the interplay between microstructure, processing history, and mechanical performance are also highly welcome.

Prof. Dr. Jin Gan
Dr. Huabing Liu
Dr. Lei Ao
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • structural integrity
  • fracture mechanics
  • fatigue analysis
  • residual stress
  • microstructure–property relationships
  • multiaxial loading
  • computational modeling
  • high-strength steels
  • lightweight alloys
  • data-driven methods

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Published Papers (5 papers)

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Research

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34 pages, 4462 KB  
Article
Data-Driven Method for Predicting S-N Curve Based on Structurally Sensitive Fatigue Parameters
by Andrey Kurkin, Alexander Khrobostov, Vyacheslav Andreev and Olga Andreeva
Metals 2025, 15(12), 1384; https://doi.org/10.3390/met15121384 - 17 Dec 2025
Cited by 1 | Viewed by 570
Abstract
Under cyclic loading, almost immediately after its onset, a surface layer forms where hardening and softening processes occur. The interaction of plastic deformation traces with each other, and with other structural elements, leads to the formation of a characteristic microstructure on the surface [...] Read more.
Under cyclic loading, almost immediately after its onset, a surface layer forms where hardening and softening processes occur. The interaction of plastic deformation traces with each other, and with other structural elements, leads to the formation of a characteristic microstructure on the surface of a component subjected to cyclic loading. The set of factors (conditions) acting during cyclic loading determines the nature of slip band accumulation, the integral structurally sensitive fatigue parameter, expressed as the slope of the left side of the fatigue curve linearized in logarithmic coordinates, and the location of the breaking point on the fatigue curve in the high-cycle region. A combined review of numerous data on the fatigue of metals, obtained under various combinations of factors, and the generalization of these results through a normalization procedure for obtaining the relative (recalculated) parameters of fatigue, allows us to derive a universal method for “S-N” curve prediction. However, extensive generalization decreases the prediction accuracy for specific cases; therefore, it is proposed to form limited generalized dependencies corresponding to specific operating conditions. This paper evaluates the accuracy of fatigue limit prediction using generalized and limited-generalized relationships of fatigue recalculated parameters for various fatigue curves obtained from independent experimental data. Full article
(This article belongs to the Special Issue Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment)
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28 pages, 6014 KB  
Article
Probabilistic Modeling of Fatigue Life Prediction of Notched Specimens Combining Highly Stressed Volume and Theory of Critical Distance Approach
by Bin Li, Peng Liu, Yuan Cheng, Xiaodi Wang and Xuechong Ren
Metals 2025, 15(12), 1300; https://doi.org/10.3390/met15121300 - 26 Nov 2025
Cited by 1 | Viewed by 832
Abstract
Notch and size effects significantly influence the fatigue performance of engineering components, which is crucial for ensuring structural integrity. A novel probabilistic fatigue life prediction Kt-V-L model considering both the size and the notch effect, based on the theory of critical distance L [...] Read more.
Notch and size effects significantly influence the fatigue performance of engineering components, which is crucial for ensuring structural integrity. A novel probabilistic fatigue life prediction Kt-V-L model considering both the size and the notch effect, based on the theory of critical distance L (TCD) and the improved highly stressed volume V (HSV) method, is proposed in this study. The new definition more accurately characterizes fatigue damage and accumulation, overcoming the underestimation issues of traditional HSV methods under high-stress or low cycle fatigue (LCF) conditions. Specifically, the Weibull distribution is also proposed to characterize the material fatigue failure probability. The experimental data of 26Cr2Ni4MoV, En3B, and TC4 materials with varying notched sizes are utilized for the model validation and comparison. In addition, the predictive ability of the point method (Kt-V-L-PM) and line method (Kt-V-L-LM) under the novel proposed model was explored and evaluated. The predicted lives of 26Cr2Ni4MoV specimens fall within the ±2 scatter band of the Kt-V-L-LM, while the Kt-V-L-PM shows increasing deviation with larger notches due to its limited ability to capture stress gradients. For En3B and TC4, the predicted lives are within ± 2 life factors, verifying the model’s reliability and accuracy. Furthermore, fracture morphology analysis reveals the influence of notches on fatigue performance and elucidates the fracture failure mechanisms. Full article
(This article belongs to the Special Issue Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment)
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17 pages, 15551 KB  
Article
Composition Optimization and Microstructure-Property Investigation of Al-3.0Ce-xCa-yMn Alloy Exhibiting High Hot Tearing Resistance
by Xiaoxiao Wei, Suhui Zhang, Xiaofei Wang, Yulin Teng, Wanwen Zhang and Mengmeng Wang
Metals 2025, 15(11), 1195; https://doi.org/10.3390/met15111195 - 27 Oct 2025
Viewed by 719
Abstract
This study employs a combined approach of theoretical calculations and experimental validation to systematically optimize the alloy composition, aiming to mitigate the hot cracking susceptibility of an Al-3.0Ce-xCa-yMn alloy in laser powder bed fusion (LPBF) processing. Through advanced characterization techniques such as electron [...] Read more.
This study employs a combined approach of theoretical calculations and experimental validation to systematically optimize the alloy composition, aiming to mitigate the hot cracking susceptibility of an Al-3.0Ce-xCa-yMn alloy in laser powder bed fusion (LPBF) processing. Through advanced characterization techniques such as electron backscatter diffraction (EBSD), transmission electron microscopy (TEM), and mechanical property testing, the intrinsic relationship between microstructure and mechanical performance was thoroughly elucidated. Computational results revealed that the addition of Ca significantly lowered the eutectic precipitation temperature, thereby effectively reducing the hot cracking tendency while maintaining a stable volume fraction of the Al11(Ce, Ca)3 phase. The optimal mass fractions of calcium (Ca) and manganese (Mn) were determined to be 0.8% and 1.9%, respectively. Microstructural characterization indicates that the alloy consisted of an α-Al matrix embedded with Al-Ce-Ca ternary eutectic compounds, and nanoscale Al6Mn spherical precipitates were uniformly distributed within the matrix. Mechanical property evaluations demonstrated that the Al-3Ce-0.8Ca-1.9Mn alloy exhibited an outstanding balance of strength and ductility at both room and elevated temperatures, with room temperature yield strength, tensile strength, and elongation values of 321 ± 15 MPa, 429 ± 8 MPa, and 10.9 ± 2.3%, respectively. This exceptional performance was attributed to a synergistic combination of multiple strengthening mechanisms including eutectic structure-induced strengthening, grain boundary strengthening due to ultrafine grains, and dislocation pinning strengthening caused by nano-sized Al6Mn precipitates. Full article
(This article belongs to the Special Issue Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment)
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20 pages, 8789 KB  
Article
The Effect of Hydrogen Embrittlement on Fracture Toughness of Cryogenic Steels
by Junggoo Park, Gyubaek An, Jeongung Park, Daehee Seong and Wonjun Jo
Metals 2025, 15(10), 1139; https://doi.org/10.3390/met15101139 - 13 Oct 2025
Cited by 4 | Viewed by 1975
Abstract
This study investigates the effect of hydrogen embrittlement on the fracture toughness of 9% Ni steel and STS 316L stainless steel under cryogenic conditions ranging from −80 °C to −253 °C. Hydrogen charging was performed using electrochemical methods, and hydrogen uptake was quantitatively [...] Read more.
This study investigates the effect of hydrogen embrittlement on the fracture toughness of 9% Ni steel and STS 316L stainless steel under cryogenic conditions ranging from −80 °C to −253 °C. Hydrogen charging was performed using electrochemical methods, and hydrogen uptake was quantitatively analyzed using thermal desorption spectroscopy (TDS). Fracture toughness was evaluated using crack tip opening displacement (CTOD) testing per ISO 12135, both without hydrogen (WO-H) and with hydrogen (W-H). The results showed a gradual decrease in CTOD values with decreasing temperature in both steels under hydrogen-free conditions, with ductile fracture maintained even at −253 °C. In contrast, hydrogen-charged specimens exhibited significant toughness degradation at intermediate subzero temperatures (−80 °C to −130 °C), particularly in 9% Ni steel due to its BCC crystal structure. However, at −160 °C and below, the effect of hydrogen embrittlement was suppressed mainly owing to the reduced hydrogen diffusivity. Scanning electron microscopy (SEM) analysis confirmed the transition from ductile to brittle fracture with decreasing temperature and hydrogen influences. At −253 °C, fully brittle fracture surfaces were observed in all specimens, confirming that at ultra-low temperatures, fracture behavior is dominated by temperature effects rather than hydrogen. These findings identify a practical temperature limit (approximately −160 °C) below which hydrogen embrittlement becomes negligible, providing critical insights for the design and application of structural materials in hydrogen cryogenic environments. Full article
(This article belongs to the Special Issue Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment)
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Review

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16 pages, 836 KB  
Review
Physics-Based Constitutive Modelling of Ductile Damage and Fracture: A Microstructure-Sensitive Perspective
by M. Amir Siddiq
Metals 2026, 16(3), 340; https://doi.org/10.3390/met16030340 - 18 Mar 2026
Viewed by 418
Abstract
Physics-based constitutive modelling remains a cornerstone for predicting ductile damage and fracture in metallic materials, particularly where microstructural mechanisms govern macroscopic response. Over the past two decades, a wide range of crystal plasticity, porous plasticity, and void-based fracture models have been proposed to [...] Read more.
Physics-based constitutive modelling remains a cornerstone for predicting ductile damage and fracture in metallic materials, particularly where microstructural mechanisms govern macroscopic response. Over the past two decades, a wide range of crystal plasticity, porous plasticity, and void-based fracture models have been proposed to capture deformation localisation, void growth, and coalescence under complex loading paths. However, these developments are often presented in isolation, obscuring their shared physical assumptions and limiting their transferability across material systems and length scales. This article provides a microstructure-sensitive perspective on the constitutive modelling of ductile damage and fracture, with particular emphasis on crystal plasticity-based frameworks, void growth and coalescence mechanisms, and interface-driven fracture. Rather than attempting an exhaustive review, this review highlights the unifying concepts, modelling trade-offs, and recurring challenges related to parameter identifiability, scale bridging, and predictive robustness. It further clarifies how physics-based constitutive descriptions can be systematically integrated into modern fatigue and fracture assessments and situates these developments relative to emerging data-assisted and machine-learning-enhanced modelling strategies. By reframing established constitutive models within a coherent physical narrative, this perspective aims to support more transparent model selection, improve interpretability, and guide future developments in the multiscale damage and fracture modelling of metallic materials. While these frameworks offer enhanced microstructure sensitivity, their parameter richness and experimental calibration demand currently limit widespread industrial deployment, motivating ongoing work on reduced-order and data-assisted variants. Full article
(This article belongs to the Special Issue Fatigue, Fracture, and Multiaxial Integrity of Metallic Structure Materials: From Microstructure to Data-Driven Assessment)
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